Oil Free Magnetic Bearing Chillers

Lloyd DavisESTech Energy Ltd

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Agenda:

• Short History of Oil Free Magnetic Bearing Compressor

• Technical Details of the Magnetic Bearing Compressor

• Smardt History and Vision

• Smardt Products Development and Quality

• Refrigerant Economizer

• Heat Recovery Application

• Smardt Modularity Application

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Prototype 3 1999

Still only 55 TR capacity.

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Turbocor factory, Dorval, Quebec 2000

39,000 sf inc development labs and test facilities

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Manufacturing development 2002

Shaft construction and heat-shrink-fitting.

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THE TURBOCOR REVOLUTION Begins

• Sustainable energy efficiency

• Oil-free

• Variable speed

• Compact

• Quiet

• Less mechanical complexity

• Maintenance “free”

• Greater value, lowest LCC

Oil-free compressor technology

Centrifugal Compressors for Air

Conditioning and Process Cooling

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The first intelligent compressor

The TT300 is the world’s first digital compressor, with:

• Digitally controlled bearings,

• Digitally controlled power electronics,

• Digitally controlled compressor control,

• Digitally controlled chiller control,

• Digitally controlled expansion valve control

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INSIDE THE COMPRESSOR

Oil Free Magnetic Bearings

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INSIDE THE COMPRESSORTwo Stage, Direct

Drive, Centrifugal

Compressor

Stage One Impeller

Stage Two Impeller

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INSIDE THE COMPRESSOR

• 97% Efficient Permanent Magnet

Motor

• Small

• 140hp motor is the size of a

conventional 1hp induction

motor.

• High speed (18,000 to 48,000 RPM

• Refrigerant-cooled, enhancing

longevity.

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INSIDE THE COMPRESSORIntegral Variable Frequency Drive

Since the motor is driven by an

integral VFD, this compressor

requires very low starting

current, drawing less than 2

amps when first energized. No

in-rush.

Well suited for applications

with emergency back-up power

systems.

Reduces thermal stresses on

motor for long-life reliability.

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INSIDE THE COMPRESSOR

• Integral Microprocessor

• Inbuilt pressure and temperature transducers

• Motor and electronics cooling circuit

• Protected DC/DC power supply

• Open communications via modbus enable LON, BACNET and other BMS applications

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TT500

TT400

TT350

TT300

0 210 [kW] 316 [kW] 422 [kW] 522 [kW] 700 [kW]

0 60 [Ton] 90 [Ton] 120 [Ton] 150 [Ton] 200 [Ton]

Nominal Compressor Capacity

COMPRESSOR CAPACITY

Turbocor Family

of Products

~ 15,000SF ~22,500SF ~30,000SF ~37,000SF ~50,000SF

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COMPACT, LIGHTWEIGHT DESIGNWeighs less than 330 lbs. for up to 200 tons

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• Annually check

electronics for tight

and moisture-

sealed connections

• No oil service or oil

disposal

• Replace capacitors

once every ten

years

MAINTENANCE

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• Key aspects of the problem – Traditional “iceberg” model stresses

lowest first cost for chillers– Major ownership costs start after

warranty expires– Chiller companies harvest high

margins from after-market parts and labor pricing

• Oil testing is a major part of long term service contracts

– ENERGY COST another major component

– Chillers evaluated at full load rather than total cost of ownership

– Artificial separation of capex and opex – planning, management and reporting

Barriers to entry created a long lag to market acceptance 2001 - 2010

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OIL FREE TECHNOLOGYOil-free water-cooled chillerTypical screw water-cooled chiller

Fewer Connections

Higher Efficiency

Simplify application and reduce cost

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Oil Impact on Energy Efficiency

For the purpose of the Life Cycle

Cost, it is assumed that 3.5% oil

concentration occurs after 2 years of

operation for flooded evaporator

systems.

“An ASHRAE study determined

that the vast majority of installed

chillers have an excess amount

of oil in the cooling system.”

ASHRAE research study 601

3.5 % of oil in the refrigerant charge

reduces system efficiencies by 8 %

4.9

22.9

16.9

7.1

17.9

12.7

9

16.7

17.8

2.9

0 5 10 15 20 25

1

2

3

4

5

6

7

8

9

10

Percent Oil

Sa

mp

le N

um

be

rs

0

2

4

6

8

10

12

14

1 2 3 4 5 6 7 8

%E

ffic

ien

cy L

oss

Percent Oil

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Performance standards have started to reflect the new market paradigm

• ASHRAE 90.1 – 2010:

– Shifts some emphasis away from the traditional “full load”

– Path A (full load) and Path B (slightly lower full load with substantially higher IPLV)

– Delivers 30% energy savings over 90-1-2004.

• New ASHRAE 90.1 – 2015

– Minimizes efficiency differences between screw and OFCC

• New whole-building standard ASHRAE 189 – in public draft Sep 2009 – reflects design approach aligned with LEED.

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• Variable speed and dual compressor control deliver

significant energy benefits, when applied to a wide range of

building types and climates.

• Oil-free design eliminates oil fouling of flooded heat

exchangers, which sustains energy efficiency over the life of

the system.

• Oil-free, magnetic bearing design has lower annual

maintenance and no periodic bearing inspections. Vibration

monitoring is built-in to the compressor as standard.

• Every project is unique, and Life Cycle Costing is a valuable

tool that can be used to look at the particular chiller options

available.

LCC of Oil Free Chillers vs. Conventional

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Oil Free Centrifugal Chillers (OFCC) represents a significant portion of the market

• OFCC represent over

50% of market share in

100 – 400 ton WCC

range

• OFCC represent about

20-25% of all WC

chillers

• Smardt has 1500 in NA

and 3500 total OFCC

chillers

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Lab testing 2001

Compressor mapping a major task for each design iteration.

Smardt have shared history and roots in Turbocor compressor and oil free chiller

development

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Global Smardt Footprint

Montreal,

Global HQ

Stuttgart,

European, HQ

Melbourne

Asia Pacific, HQ

Guangzhou,

ChinaDubai, Sales

Operation

Singapore, Sales

Operation

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Smardt Chillers innovate the Turbocor compressor into the widest variety of

configurations• Comprehensive manufacturing capability

• Most innovative controller

• Water Cooled

• Air Cooled

• Condenserless

• Heat Recovery

• Free Cooling

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Smardt has comprehensive and fully integrated manufacturing capability

Leading OFCC.

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Testing facility capable of performing load test up to 1200 tons.

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Smardt chiller controller graphics package leads the industry, for data acquisition,

intuition and flow

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Oil Free Magnetic Bearing Air Cooled Chillers Lead in Efficiency and Sound

• Full Load EER of 12

• IPLV EER over 22

•Quietest air cooled chiller – less than 85 DBa

• No additional sound wrapping or attenuation

needed

• Low flow condenser

• Free cooling, all air cooled models

• Single circuit

• Dual circuit for models with even qty of

compressors

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A quiet chiller means never having to shout about its performance

The traditional definition of noise is “unwanted or disturbing sound”. Sound becomes unwanted when it either interferes with normal activities such as sleeping, conversation, or disrupts or diminishes one’s quality of life.

Noise pollution adversely affects the lives of millions of people. Studies have shown that there are direct links between noise and health. Problems related to noise include stress related illnesses, high blood pressure, speech interference, hearing loss, sleep disruption, and lost productivity. Noise Induced Hearing Loss (NIHL) is the most common and often discussed health effect, but research has shown that exposure to constant or high levels of noise can cause countless adverse health affects.

Source – US EPA

As a reference ASHARE Fundamentals

Handbook lists various sound power

sources, a voice shouting has a sound

power of 90 dBA

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Smardt Nano coated condenser is another innovation in achieving the lowest total

cost of ownership for Smardt air cooled chillers.Smardt provides an optional nano-polymer coating. This innovative nanotechnology lowers the surface energy of aluminum fins protecting them from corrosion and water damage. Nano coating is only 5µ thin with high heat transfer capabilities. It resists corrosion, salt water, and dust; Salt Spray test results are superior achieving over 3,000 hours resistance and counting.

Repelling water and dirt is a key factor in keeping your air cooled chiller as efficient as the first day it was installed.

Nano coating prevents the adhering of the water droplets on the fin surface, keeping the fin from accumulating dust and water.

On uncoated fins, water droplets accumulate which can restrict air flow, cause pitting, corrosion and produce water spray.

Smardt performed side by side exposure testing in the harsh environment aircraft environment at a local municipal airport to demonstrate the difference in benefits of Nano condenser coatings. After 7 months the Nano coated fin was as clean as the first day, while the uncoated fin showed clear evidence of pitting, corrosion and dust accumulation.

Nano Coated fin Uncoated fin

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Another Innovation - Refrigerant Economizer for Water Cooled

• Only design with multiple compressors and flash economizer

• This feature provides advantages of capacity and efficiency improvement of 5% and 7% at full load respectively when an economizer is installed

• Lower the operating costs

• Available from 200 Tons to 500 Tons capacity now, and up to 1100 TR in the future

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Economizer improvement in efficiency in two typical sizes.

Smardt Model

Eff Max Cap

Additional Features

WA 096.2H 0.643 290 Previous non-econ performance

WA 096.2H ECON

0.606 310 New Econ Performance-Most efficient, stretches capacity above 300 tons

WA 130.2L .618 390 Previous non-econ performance

WA 130.2L ECON

.578 400 Most efficient with econ, 4% more efficient than

WMC 400

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Refrigerant Economizer for Air cooled chiller

• This feature provides advantages of capacity and efficiency improvement of 9% to 12 % at full load respectively when an economizer is installed

• Inexpensive and more reliable than over sizing the unit in order to maintain a lower kw/ton at full load.

• Available from 80 ton to 455 TR air cooled units Tons capacity

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Innovation Continues –Largest Multiple Compressor Heat

Recovery

• Smardt has built chillers

using Turbocor for heat

recovery starting in 2009

• Single and Dual vessel

designs

• Maximum hot water

temperature 110-115F

• Latest project to be

delivered in Mar 2014

• 8 compressors

• 1100 TR Cooling

• 400 TR Heat Recovery

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Smardt Air Cooled Chillers with Heat Recovery

Available in sizes up to 300 tons

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• Integrated pump package

• Single Source Power

• Dual pump design

• Integrated VFD

• Sensorless VFD: no need

to wire any sensor back to

the pump

• Automatic variable flow

control

• Chiller sizes up to 400 TR

• Available Feb 1SmardtModels

GPM Range

Head Range

AC028.1B.4A 90 – 192 25 - 125

AC040.1E.8A 150 – 275 25 - 125

AC054.2B.8A 225 – 384 25 - 125

AC065.2E.10A 270 – 432 25 - 125

AC080.2E.12A 300 – 480 25 – 125

AC086.3B.12A 330 – 528 25 – 125

AC120.3E.16A 360 – 576 25 – 125

AC 150.3E.20A 600 – 960 25 - 125

48”

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Multiple Compressors, no risk

of cross contamination

Multiple Serviceable Expansion

Valves

Multiple circuits, controls and

electrical systems, vessels

Simplified Designs using Oil Free Chillers – N+1 is achieved without adding another chiller.

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Level control chamber directly measure refrigerant in vessel

• Not provided, use a calculated superheat value to determine liquid level

Smardt Competitors

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1800 Trans Canada Highway

Dorval, Quebec H9P 1H7

Phone: (514) 426-8989

Fax: (514) 416-5757

www.smardt.com

•Very Efficient

•Low Maintenance

•Flexible Design

•Extremely Quiet